Surfactant modified oils for dust control of loose-fill insulation

ABSTRACT

The present invention serves to substantially improve the dust capture property of dedusting oils, by modifying these oils with nonionic and/or cationic surfactants. The application of surfactant modified oils reduces dust that is generated when loose-fill insulation is installed.

FIELD OF THE INVENTION

[0001] The present invention relates to methods for improving the dustcapture properties of dedusting oils, which properties are useful in themanufacture and installation of loose-fill insulation.

BACKGROUND OF THE INVENTION

[0002] Over the past 40 years, many homeowners have begun to installextra insulation in their attics or crawlspaces in an effort to savemoney on heating bills. Typically, new construction is thoroughlyinsulated in accordance with applicable building codes and industrystandards. A common form of insulation used by consumers and insulationcontractors has been fiberglass insulation batts and blankets. However,insulation batts are relatively expensive and may require some cuttingand shaping during installation.

[0003] More recently, the use of glass fiber blowing wool or loose-fillinsulation has increased in popularity. Loose-fill, fiberglassinsulation exists in many forms. Bonded and non-bonded loose-fillfiberglass are commonly used terms to describe loose-fill insulationproducts. Bonded loose-fill insulation is derived from blanket or battinsulation which has been made with a thermoset binder. It is producedby either pulverizing or cutting the blanket or batt insulation,compressing the resulting product and packaging it into bags.Non-bonded, loose-fill insulation comprises smaller nodules oftraditional, straight, short fibers which are treated with a dedustingoil, compressed, and packaged into bags. Both bonded and non-bondedloose fill insulations can be installed in attics and sidewalls using apneumatic blowing machine.

[0004] Loose-fill insulation is popular with insulation contractorsbecause it can be easily and quickly applied in both new construction aswell as in existing structures. Further, loose-fill insulation is arelatively low cost material. However, fiberglass loose-fill insulationis typically applied by contractors rather than homeowners because ofthe special blowing equipment needed. Such insulation is typicallypackaged in large bags weighing e.g., 25-35 lbs.

[0005] Cellulose loose-fill insulation is another type of insulationcommonly used by consumers, which is formed from shredded, recyclednewspapers. Cellulose insulation is desirable for installation byconsumers as it is available in smaller packages and is less expensivethan most other forms of loose-fill insulation. However, such insulationis dusty, dirty and difficult to blow properly, and also requiresspecial blowing equipment to install.

[0006] When loose-fill insulations are pneumatically applied, they canbe the source of dust and irritation for the installer. While dedustingoils are typically applied at the time of manufacture to control thisdust, and the installers are advised to wear a dust mask and protectivegear to reduce their exposure to dust, the effectiveness of these oilscould be improved, especially when the oils are applied at lowapplication rates (e.g., less than about 2% by weight).

SUMMARY OF THE INVENTION

[0007] The purpose of the present invention is to substantially improvethe dust capture properties of dedusting oils by modifying these oilswith nonionic and/or cationic surfactants. These surfactants may beadded individually, or in combination to the dedusting oils. Theapplication of surfactant modified oils reduces the airborne dust thatis generated when loose-fill insulation is installed pneumatically.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0008] The present invention serves to substantially improve the dustcapture property of dedusting oils, by modifying these oils witheffective amounts of nonionic or cationic surfactants. In testing of thepresent invention, oils which were modified with various surfactantswere applied through an oil application system onto non-bonded,loose-fill insulation, at a preferred amount of approximately 2% byweight using either air atomized or hydraulic pressure nozzles. One suchoil is commercially available as Telura™ 720B from Exxon MobilCorporation. The non-bonded, loose-fill material was packaged and testedfor its dust generation characteristics. When compared to a controlmaterial made with an unmodified paraffin oil with a viscosity of 100SUS, the non-bonded, loose-fill product made with the surfactantmodified oil exhibited substantially lower dust levels. Furthermore, bythe method of the present invention, the surfactant modified oils reducedust levels of insulation that are produced over a range of fiberizingconditions.

[0009] Note that the treatment of the present invention should beapplied to loose-fill insulation at a temperature at or above about 80°F., preferably from about 80-110° F.

[0010] The following testing demonstrates that the use of surfactantmodified oils significantly reduced the airborne dust levels of a sampleof thermal insulation product, as compared to similar insulations madewith conventional dedusting oils. Dust levels were measured using themethodology as disclosed in U.S. Pat. Nos. 6,005,662 and 6,122,054,herein incorporated by reference. Two distinct fiberizing conditionswere tested. One condition had a fiber fineness index of 2.9 and theother had a fineness index of 2.65 when measured by ASTM D1488-97standard test method for micronaire reading of cotton fibers. Ingeneral, finer fibers tend to produce more dust.

[0011] Table 1 shows the % increase in dust reduction when loose-fillinsulation made with the experimental oils was compared to loose fillinsulation using the standard dedusting oil, Prorex 100 made by ExxonMobil. TABLE 1 % Dust Reduction Measured versus Standard Dust ControlOil (Control) Fiber % Oil Applied % Increase in Treatment Fineness toLoose Fill Dust Reduction Standard Dust Control Oil¹ 2.90 2.00 ControlSurfactant Modified Oil - 2.90 1.90 28% Telura 720E² Standard DustControl Oil¹ 2.65 1.87 Control Surfactant Modified Oil - 2.65 1.87 53%Telura 720E² Surfactant Modified Oil - 2.65 1.80 46% Telura 720E³Standard Oil Modified with 2.65 1.97 25% a Cationic Surfactant⁴

[0012] As noted above, in a preferred embodiment of the presentinvention, the surfactant modified oil tested was a standard dustcontrol oil, modified to include 2% by weight of glycerol monooleate, anonionic surfactant. Percents by weight of surfactant may range fromabout 0.5-10%. It is anticipated that alternative nonionic surfactantswould also be effective, e.g., mono-, di-, and tri-fatty acid esters ofglycerol and modified esters of this type, so long as effective amountsof such surfactants were applied.

[0013] In a preferred embodiment of the present invention, the nonionicsurfactant is a monoester of an unsaturated or saturated acid. Theunsaturated acid may be e.g., linoleic or linolenic acid. The saturatedacid may be e.g., a C12 to C18 lauric, myristic, palmitic or stearicacid. In a further preferred embodiment, the nonionic surfactant is adiester or triester of an unsaturated or saturated acid.

[0014] As it relates to the loose-fill insulation, it is preferred thatthe modified oil be applied to the loose-fill insulation at from about0.5-2.5% by weight, with an amount of about 2.0% by weight particularlypreferred.

[0015] While this invention has been described with respect toparticular embodiments thereof, it is apparent that numerous other formsand modifications of this invention will be obvious to those skilled inthe art. The appended claims and this invention generally should beconstrued to cover all such obvious forms and modifications which arewithin the true spirit and scope of the present invention.

We claim:
 1. A method of controlling dust formation in loose-fillinsulation, comprising applying to said loose-fill insulation a dustinhibiting amount of a combination of a dedusting oil and a surfactant.2. The method as recited in claim 1, wherein said combination is appliedto said loose-fill insulation in an amount of from about 0.5-2.5% byweight.
 3. The method as recited in claim 1, wherein said surfactant isnonionic.
 4. The method as recited in claim 1, wherein said surfactantis cationic.
 5. The method as recited in claim 1, wherein saidinsulation is installed pneumatically.
 6. The method as recited in claim3, wherein said surfactant is glycerol monooleate.
 7. The method isrecited in claim 1, wherein said combination is applied to saidloose-fill insulation in an amount of about 2% by weight.
 8. The methodas recited in claim 3 wherein said nonionic surfactant is a monoester ofan unsaturated or saturated acid.
 9. The method as recited in claim 8wherein said unsaturated acid is linoleic or linolenic acid.
 10. Themethod as recited in claim 8 wherein said saturated acid is a C12 to C18lauric, myristic, palmitic to stearic acid.
 11. The method as recited inclaim 3 wherein said nonionic surfactant is a diester or triester of anunsaturated or saturated acid.
 12. A method of controlling dustformation in loose-fill insulation, comprising applying to saidloose-fill insulation a dust inhibiting amount of a combination of adedusting oil and a nonionic surfactant.
 13. The method as recited inclaim 12, wherein said insulation is installed pneumatically.
 14. Themethod as recited in claim 13, wherein said combination is applied tosaid loose-fill insulation in an amount of from about 1.5-2.5% byweight.
 15. The method as recited in claim 13, wherein said nonionicsurfactant is glycerol monooleate.
 16. The method as recited in claim 12wherein said nonionic surfactant is a monoester of an unsaturated orsaturated acid.
 17. The method as recited in claim 13 wherein saidunsaturated acid is linoleic or linolenic acid.
 18. The method asrecited in claim 13 wherein said saturated acid is a C12 to C18 lauric,myristic, palmitic to stearic acid.
 19. The method as recited in claim12 wherein said nonionic surfactant is a diester or triester of anunsaturated or saturated acid.